Recall 0632 – Brake Fluid Warning Decals – 2021-2022 Harley-Davidson XL1200X, XL883N, & 2021 XL1200NS XL Sportster Motorcycles

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March 16, 2022 NHTSA CAMPAIGN NUMBER: 22V160000

Brake Fluid Warning Labels May Detach/FMVSS 122

Missing brake fluideBay warning labels may lead to improper brake system maintenance, affecting brake performance and increasing the risk of a crash.

 

NHTSA Campaign Number: 22V160

Manufacturer Harley-DavidsoneBay Motor Company

Components SERVICE BRAKES, HYDRAULIC, EQUIPMENT

Potential Number of Units Affected 4,177

 

Summary

Harley-DavidsoneBay Motor Company (Harley-DavidsoneBay) is recalling certain 2021-2022 XL1200X, XL883N, and 2021 XL1200NS XL Sportster motorcycles. The brake fluideBay warning labels may detach from the brake fluideBay reservoir caps. As such, these motorcycles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 122, “Motorcycle Brake Systems.”

 

Remedy

Harley-DavidsoneBay will mail replacement labels to owners, free of charge. Owners may also take their motorcycles to a dealer for label inspection and replacement, free of charge. Owner notification letters were mailed April 4, 2022. Harley’s number for this recall is 0632.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check for Harley-Davidson Recalls

 


Supplemental Procedure Video

WARNING

Always review the appropriate service procedure prior to performing it. This video is intended to supplement, not replace, documented service procedures. Attempting service procedures without the proper training, tools, equipment, and manuals could result in death or injury to you or others. This could also damage the motorcycle or cause the motorcycle to operate improperly. (10406a)

 

This video is a supplement of the procedure covered in the document. This video can only be viewed through Service Information Portal (SIP).

https://serviceinfo.harley-davidson.com/sip/content/document/ view?id=1615454891662166318

 

Purpose for Service Bulletin

This bulletin informs dealers that Harley-DavidsoneBay has learned that certain 2021 and 2022 XL Sportster motorcycles may not be compliant with Federal Motor Vehicle Safety Standard (FMVSS) No. 122, Motorcycle Brake Systems. Due to a non-uniform edge, the brake fluideBay warning decal(s) may not be adequately affixed to the front and rear brake master cylinder cover.

 

Motorcycles Affected

2021 and 2022 Sportster XL models.

 

Inspect

1. Try to remove the decal from front and rear brake master cylinder fluid cover with a finger nail.

2. If the decal cannot be removed with a finger nail, no further action is required.

 

Failure

1. If the decal begins to lift from the front or rear master cylinder cover, completely remove the decal.

 

NOTE

  • Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components may occur.
  • For maximum bond, surface must be clean and dry.

2. Ensure that surface is clean and dry.

 

Install Decal

NOTE

  • Apply in ambient temperatures between 21โ€“38 ยฐC (70โ€“100 ยฐF).
  • Parts cannot be repositioned after initial installation. Do not remove protective film from adhesive until ready to apply.
  • Do not bend emblem to fit contour of mounting surface.
  • Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
  • The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.

 

1. Remove protective film from back of decal.

NOTE

  • Protect adhesive from grease, oil, dust, dirt and fingerprints.
  • Once applied, do not shift decal.

2. Position decal in center of master cylinder fluid cover relief.

3. Apply even pressure across entire surface. Hold in place for 15 seconds.

4. Wait 20 minutes before touching decal.

5. If needed, repeat steps 1-4 for other master cylinder fluid cover relief.

 


Chronology :

02/03/2022 – Harley-DavidsoneBayโ€™s Technical Subcommittee (TSC) was made aware of a potential issue with MY22 XL (all models) built at York Vehicle Operations. An audit performed on 01/28/2022 revealed that the brake fluideBay warning decal, part number 44791-07 (DECAL, FRT MSTR CYL/DOT 4), was missing from the front brake master cylinder cap on one of the vehicles inspected during the audit.

02/03/2022 – 02/28/2022 – The TSC conducted a root cause and scope analysis. This included an audit of vehicles as well as discussions with the supplier. The TSCโ€™s investigation indicated that due to a non-uniform edge on the decal, the brake fluideBay warning statement on some of these vehicles may not be permanently affixed.

03/03/2022 โ€“ The Field Action Committee (FAC) reviewed the TSCโ€™s findings and analysis and escalated the matter to H-Dโ€™s Executive Decision Authority (EDA).

03/08/2022 โ€“ Based upon the information developed during the investigation, the EDA determined that this condition may constitute a noncompliance with FMVSS 122, S5.1.9, and authorized a recall to address this condition. There have been no reports of any accidents or injuries related to this issue.

 


5 Affected Products

Vehicles

MAKEMODELYEAR
HARLEY-DAVIDSONeBayXL1200NS2021
HARLEY-DAVIDSONeBayXL1200X2021-2022
HARLEY-DAVIDSONeBayXL883N2021-2022

 


8 Associated Documents

Noncompliance Notice 573 Report

RCLRPT-22V160-3532.PDF 217.992KB

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Recall Acknowledgement

RCAK-22V160-1787.pdf 645.505KB

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Recall 573 Report – March 24, 2022

RCLRPT-22V160-8153.PDF 218.05KB

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Remedy Instructions and TSB

RCRIT-22V160-7447.pdf 125.805KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V160-3359.pdf 118.411KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V160-3233.pdf 301.768KB

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Recall Quarterly Report #1, 2022-2

RCLQRT-22V160-4901.PDF 211.152KB

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Recall Quarterly Report #3, 2022-4

RCLQRT-22V160-2148.PDF 211.333KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V160&docType=RCL


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Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API


 

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